Wall repair system

ABSTRACT

A wall repair system is disclosed. The wall repair system includes a patch and a rigid patch support having a proximal end and a distal end. The rigid patch support having a length substantially equal to the gap between a first inner surface and a second inner surface of the wall being repaired. The distal end has at least one wall engagement member capable of securing the distal end to second inner surface. The system also includes means for securing the patch to the proximal end of the rigid patch support.

FIELD OF THE INVENTION

The present invention relates to repairing damaged walls, and morespecifically to repairing damaged drywall walls, particularly drywallwalls damaged by a door knob or similarly sized object.

DESCRIPTION OF THE RELATED ART

In the late 1940's the use of gypsum board panels, typically referred toas “sheetrock” or “drywall”, became the preferred building material forinterior walls and partitions in most types of buildings in the UnitedStates, primarily because of the relatively low cost of material andinstallation. These panels are essentially made of a hardenedplaster-like gypsum material which is sandwiched between sheets of paperor cardboard material. Sheetrock panels, which can by cut to size usingonly a utility knife, are typically nailed or screwed to spaced woodenstuds or joists to provide a flat wall or ceiling surface which spansthese wooden supporting members, leaving the space between the studs orjoists hollow behind the wall surface. The surface of a sheetrock wallis typically finished by filling irregularities and indentations, suchas those in the areas where nails or screws have been driven through theface of the panel. The slight gaps between panels are similarly filledand taped over using paper tape which is sufficiently wide to bridge thegap between panels and which is held in place by the filler material.The filler is “drywall compound,” a mud-like material which is smoothedinto place and allowed to dry and harden. However, even the dried fillermaterial has relatively little structural integrity and providesprimarily the cosmetic benefit of a smooth wall or ceiling surface. Thefiller material by itself also has a tendency to shrink somewhat whiledrying and is therefore susceptible to cracking, particularly where itis used in large quantities or in thick layers.

Sheetrock panels installed in this manner serve well for interior use aswalls and ceilings. A typical interior wall will have two external wallsurfaces, each wall surface being the external surface of one of twoparallel sheetrock panels which are spaced apart and secured to oppositesides of the wooden studs.

The primary drawback to using sheetrock material is that it is easilydamaged by a sudden blow applied to a small area, such as that which maybe caused by the protruding door knob of a swinging door. The materialis also susceptible to being puncturing by sharp objects. Also, removalor relocation of an electrical outlet or switch box during remodelingmay leave a hole that must be filled or covered.

A simple, easy to use and inexpensive method for repairing holes insheetrock walls to restore the damaged or missing part of the wallboard,has eluded inventors, drywall professionals, handymen-homeowners, andbuilding maintenance personnel, for as long as such materials have beenin common use. Such repair can be relatively difficult, especially inthe most common situation where the hole is located over the voidbetween two wall studs and extends completely through the drywall intothis void. In such a situation, and particularly if the hole is greaterthan about one (1) inch in diameter, the use of any semi-liquid orpaste-like hardening filler material such as drywall compound, plaster,or spackling compound is generally not practical, since the void behindthe hole provides no support for the filler, thus allowing the filler tofall through into the hollow space behind the hole. Additionally, thereoften exists an air pressure differential between the void inside thewall and the room. This air pressure differential can push the fillerinto or out of the hole. Previously, similar difficulties have arisen inconnection with using a solid patching material such as a piece of woodor drywall since there has been no convenient way of both positioningthe patch flush with the outer face of the wall surface and supportingit in place.

Over time, various methods and systems have been developed to attempt torepairs holes in drywall. One of the most common methods involvesstuffing wadded up newspapers, cloths, or other similar items into thehole and then covering the hole with filler compound with the hope thatthe wadded up material will provide enough support for the fillercompound to set and seal the hole. Another common method involvesremoving a large enough section of the damaged drywall to allow thepatch to be nailed or screwed into the surrounding studs or joists.

Additionally, various U.S. patents have been issued on systems andmethods of repairing damaged wallboard. For example, U.S. Pat. No.3,936,988, discloses a repair device used to restore a damaged drywallboard, wherein a 2.5 inch or larger hole is cut out from the damagedwall. A cut out piece of wallboard of slightly smaller dimensions thanthe hole is used to effect the restoration in conjunction with therepair device. The repair device consists of a wallboard support memberthat inserts through the hole to be secured onto the inside surface of arear drywall. The cut out piece of wallboard is secured to the boardsupport member. A plurality of clip members are affixed onto the cutoutpiece of wallboard, wherein the clip members engage an inside surface ofthe damaged wall board. The cut out piece of wallboard is recessedinward from the front face of the damaged drywall. A user plastersmaterial into the recess and onto the cut out piece of wallboard. Theclip members and board support member become an integral part of therestored wallboard.

Another example is found in U.S. Pat. No. 5,269,861, which discloses astructure and method for repairing a damaged section in a sheetrock wallor ceiling comprising removal of the damaged section by cutting out aspecifically-sized section of the wall surrounding the damaged section,providing a like-size, tight-fitting replacement section in the cutoutarea, providing a combination of fabric strips impregnated with anunactivated fast-setting plaster or cementitious material, providing awater-based glue, coating the edges of the replacement section and thecutout area with the water-based glue, activating the cementitiousmaterial, positioning fabric strips on the back side of the replacementpatch with ends of the strips extending beyond each edge of thereplacement patch, inserting the replacement section of sheetrock intothe cutout area and manipulating it into flush alignment with the wallsurface by manually gripping the patch assembly using the extendedportions of the plaster impregnated strips, flattening the extendedportions of the strips against the wall surface, allowing thecementitious material and water-based glue to harden, and trimming awayexposed portions of the strips on the wall surface, thus creating asecurely bonded integral patched part of the sheetrock, which restoresthe panel to near its original strength and finish.

Unfortunately, each of these systems and methods do not providesufficient support of the repaired area to resist being damaged again.As mentioned above, one of the common causes of damage to drywall isdoor knob strikes. Since it is more likely than not that the door knobwill strike the repaired area again, the repaired area needs to be ableto resist being damaged again. Using the methods and systems describedabove, the repaired area is weaker, not stronger, than the originalundamaged wall in that area.

Accordingly, there remains a need for a wall repair system thatadequately supports the patch and results in the repaired area beingstronger than the original, undamaged wall in that area. There alsoremains a need for a wall repair system that provides sufficient supportof the repaired area to resists being damaged again.

SUMMARY

In view of the deficiencies described above, it is an object of thepresent invention to provide a wall repair system that adequatelysupports the patch and results in the repaired area being stronger thanthe original, undamaged wall in that area.

It is a further object of the present invention to provide a wall repairsystem that provides sufficient support of the repaired area to resistsbeing damaged again.

The present invention is a wall repair system. The wall repair systemincludes a patch and a rigid patch support having a proximal end and adistal end. The rigid patch support having a length substantially equalto the gap between a first inner surface and a second inner surface ofthe wall being repaired. The distal end has at least one wall engagementmember capable of securing the distal end to second inner surface. Thesystem also includes means for securing the patch to the proximal end ofthe rigid patch support.

Preferably, the patch is made from drywall having a desired shape forthe patch. In various preferred embodiments, the patch is asubstantially circular disc of drywall.

The wall engagement members can include at least one spike suitable forpenetrating the second inner surface of the second wall portion of thewall being repaired and firmly securing the rigid patch support to thesecond inner surface.

The means for securing the patch to the proximal end of the rigid patchsupport can include a screw, such as a common drywall screw. In othervarious preferred embodiments, the patch can be secured to the proximalend of the rigid patch support with an adhesive.

The wall repair system of the present invention can be used according tothe following process. First, the damaged section is cut out from thefirst wall portion, if needed, thus forming a hole in the first wallportion. Next, the rigid patch support is inserted into the hole and thedistal end of the rigid patch support is secured to the second innersurface of the second wall portion using at least one wall engagementmember. Now the patch is inserted into the hole and the patch is securedto the rigid patch support using any of the techniques described above.Lastly, the interface between the patch and the first wall portion isfinished off.

Once installed, the wall repair system of the present invention isstronger than the original, undamaged, wall in the area of the repair.This result is achieved through the use of the rigid patch support tohold the patch in place and brace the patch against further impacts, aresult not achieved by other wall repair systems.

Other features and advantages of the invention will be apparent from thefollowing detailed description taken in conjunction with the followingfigures, wherein like reference numerals represent like features.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a wall repair system according to the present invention.

FIG. 2 shows and alternate embodiment of a wall repair system accordingto the present invention.

FIGS. 3-7 show the process of repairing a damaged wall using a wallrepair system according to the present invention.

FIG. 8 shows a side view of a completed wall repair using a wall repairsystem according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiments in many differentforms, there are shown in the drawings and will herein be described indetail, preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

The present invention is a wall repair system. The wall repair system ofthe present invention is best suited to repair a damaged section of awall constructed using conventional construction techniques. Wall ofthis type are shown in FIGS. 3-8. Walls constructed using conventionalconstruction techniques have a first wall portion 200, usually ofdrywall, which has a first outer surface 202 and a first inner surface204. There is also a second wall portion 210, also usually of drywall,which has a second outer surface 212 and a second inner surface 214. Agap 225 exists between the first inner surface 204 and the second innersurface 214. The gap 225 is created by studs 220, which form theframework for the wall and onto which the first wall portion 200 and thesecond wall portion 210 are affixed. In the United States, studs 220,and thus the gap 225, typically are 3.5 inches wide.

The wall repair system, as shown in FIG. 1, includes a patch 100 and arigid patch support 110 having a proximal end 112 and a distal end 114.The rigid patch support 110 having a length substantially equal to thegap 225 between the first inner surface 204 and the second inner surface214. The distal end 114 has at least one wall engagement member 120capable of securing the distal end 114 to second inner surface 214. Thesystem also includes means for securing the patch 100 to the proximalend 112 of the rigid patch support 110. In various preferredembodiments, the length of rigid patch support 110 may be adjustable toaccount for variations in the thicknesses of the gap 225 and the firstwall portion 200.

Preferably, the patch 100 is made from drywall having a desired shapefor the patch 100. In various preferred embodiments, the patch 100 is asubstantially circular disc of drywall. On other various preferredembodiments, the patch 100 can be rectangular, triangular, or square inshape, or can have any other desired shape.

The wall engagement member 120 or members 120 can include at least onespike suitable for penetrating the second inner surface 214 into thesecond wall portion 210 and firmly securing the rigid patch support 110to the second inner surface 214. In various preferred embodiments, thewall engagement member 120 can include a screw 130, as shown in FIG. 2.Preferably screw 130 would be located along the centerline of the rigidpatch support 110. In other various preferred embodiments, the wallengagement member 120 can be selectively removed from the rigid patchsupport, which, among other things, permits test fitting of the wallrepair system.

The means for securing the patch 100 to the proximal end 112 of therigid patch support 110 can include a screw 140, such as a commondrywall screw. In various preferred embodiments, the patch 100 caninclude preformed hole 102 for receiving the screw 140. Also, theproximal end 112 of the rigid patch support 110 can have a hole 104 forreceiving the screw 140. Optionally, screw 140 can be used as a handlefor holding and or positioning the rigid patch support 110 duringinstallation. In other various preferred embodiments, the patch 100 canbe secured to the proximal end 112 of the rigid patch support 100 withan adhesive. Other securing means known in the art may also be used.

In various preferred embodiments, one or more layers of tape 105, cloth,or other similar material can be applied around the perimeter of thepatch 100 to ensure a tight fit of the patch 100 into the hole 240.Additionally, this tape 105 can also seal any air gaps between the patch100 and the hole 240 and thus prevent or minimize any effects on plasteror compound used to finish the wall repair caused by an air pressuredifferential between the gap 225 and the first outer surface 202.

The wall repair system of the present invention can be used according tothe process shown in FIGS. 3-7. First, the damaged section 230 is cutout from the first wall portion 200, if needed, thus forming a hole 240in the first wall portion 200. The patch 100 can be used as a templatefor tracing the perimeter of the patch 100 to indicate where to cut outthe damaged section 230. This insures that the hole 240 will besubstantially the same size and shape as the patch 100, which willfurther facilitate fitting the patch 100 into the hole 240 later on.

Next, the rigid patch support 110 is inserted into the hole 240 and thedistal end 114 of the rigid patch support 110 is secured to the secondinner surface 214 of the second wall portion 210 using at least one wallengagement member 120. If needed, the length of the rigid patch support110 may be adjusted.

Now the patch 100 is inserted into the hole 240 and the patch 100 issecured to the rigid patch support 110 using any of the techniquesdescribed above. In various preferred embodiments, any air gaps betweenthe patch 100 and the hole 240 can be sealed with one or more layers oftape 105, cloth, or similar material wrapped around the perimeter of thepatch 100.

Lastly, the interface between the patch 100 and the first wall portion200 is finished off. This can be accomplished by using joint or fillingcompound to seal the perimeter of the patch 100 to the edge of the hole240 and sealing any openings between the two. Once dried, sanded,painted or otherwise finished, the repaired area should beindistinguishable from the remainder of the first wall portion 200.

Once installed, the wall repair system of the present invention isstronger than the original, undamaged, wall in the area of the repair.This result is achieved through the use of the rigid patch support 110to hold the patch 100 in place and brace the patch against furtherimpacts, a result not achieved by other wall repair systems.

While specific embodiments have been illustrated and described, numerousmodifications come to mind without significantly departing from thespirit of the invention and the scope of protection is limited by thescope of the accompanying claims.

1. A wall repair system for a wall comprising a first wall portionhaving a first outer surface and a first inner surface and a second wallportion having a second outer surface and a second inner surface,wherein a gap exists between said first inner surface and said secondinner surface, and wherein a damaged section exists in said first wallportion, said wall repair system comprising: a patch, a rigid patchsupport having a proximal end and a distal end, said rigid patch supporthaving a length substantially equal to said gap between said first innersurface and said second inner surface, wherein said distal end has atleast one wall engagement member capable of securing said distal end tosaid second inner surface, and means for securing said patch to saidproximal end of said rigid patch support.
 2. The wall repair systemaccording to claim 1, wherein a length of said rigid patch support isadjustable.
 3. The wall repair system according to claim 1, wherein saidpatch comprises drywall in a desired shape.
 4. The wall repair systemaccording to claim 1, wherein said patch comprises a substantiallycircular disc of drywall.
 5. The wall repair system according to claim1, wherein said at least one wall engagement member comprises at leastone spike.
 6. The wall repair system according to claim 1, wherein saidat least one wall engagement member comprises at least one screw.
 7. Thewall repair system according to claim 1, wherein said means for securingsaid patch to said proximal end of said rigid patch support comprises ascrew.
 8. The wall repair system according to claim 7, wherein saidpatch comprises a hole for receiving said screw.
 9. The wall repairsystem according to claim 7, wherein said proximal end of said rigidpatch support comprises a hole for receiving said screw.
 10. The wallrepair system according to claim 8, wherein said proximal end of saidrigid patch support comprises a hole for receiving said screw.
 11. Thewall repair system according to claim 1, wherein said means for securingsaid patch to said proximal end of said rigid patch support comprises anadhesive.
 12. The wall repair system according to claim 1, furthercomprising sealing means for wrapping around a perimeter of said patch.13. The wall repair system according to claim 12, wherein said sealingmeans comprises tape.
 14. The wall repair system according to claim 12,wherein said sealing means comprises cloth.
 15. A method of repairing adamaged section of a wall comprising a first wall portion having a firstouter surface and a first inner surface and a second wall portion havinga second outer surface and a second inner surface, wherein a gap existsbetween said first inner surface and said second inner surface, andwherein said damaged section exists in said first wall portion, saidmethod comprising the steps of: cutting said damaged section from saidfirst wall portion, forming a hole in said first wall portion, insertinga rigid patch support into said hole, wherein said rigid patch supporthas a proximal end and a distal end, said rigid patch support having alength substantially equal to said gap between said first inner surfaceand said second inner surface, securing said rigid patch support to saidsecond inner surface of said second wall portion, inserting said patchinto said hole, securing said patch to said rigid patch support, andfinishing an interface between said patch and said first wall portion.16. The method of repairing a damaged section of a wall according toclaim 15, further comprising using said patch as a template, tracing aperimeter of said patch to mark a location for said hole prior tocutting said damaged section from said first wall portion.
 17. Themethod of repairing a damaged section of a wall according to claim 15,wherein securing said patch to said rigid patch support comprisessecuring said patch to said rigid patch support with a screw.
 18. Themethod of repairing a damaged section of a wall according to claim 15,wherein securing said patch to said rigid patch support comprisessecuring said patch to said rigid patch support with an adhesive. 19.The method of repairing a damaged section of wall according to claim 15further comprising sealing any air gaps between said patch and said holevia wrapping a perimeter of said patch with a sealing means.
 20. Themethod of repairing a damaged section of wall according to claim 19,wherein said sealing means comprises tape.